johnson controls variable speed drives series ii

JC-VSD Series II IntelliPass®/IntelliDisconnect®Frames 4-7 Type 1 & 12

Johnson Controls Variable Speed Drives Series II IntelliPass®/IntelliDisconnect®Frames 4-7 Type 1, 12 & 3R

Drives

Important Notice – Please Read

The product discussed in this literature is subject to terms and conditions outlined in Johnson Control Inc. selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Johnson Control Inc. selling policy.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN.

In no event will Johnson Control Inc. be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the informa-tion, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice.

Safety

Read and follow all safety information shown in the JC-VSD Series II installation Manual LIT-12011775.

2

Important Notice – Please Read

JC-VSD Series II IntelliPass®/IntelliDisconnect® LIT-12011775 April 2013 www.johnsoncontrols.com

Contents

INTRODUCTIONGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Catalog / Style Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

IDENTIFICATIONUnit ID labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

FACTORY WIRED OPTIONSP3-Drives Isolation Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

P4-Drive Output contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

P6-Drives Isolation Contactor includes Drive test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

P7-Drive Output Control and Isolation Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

M1-Manual Bypass (forced) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Space Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

L3/L4-HMAX Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

PLUG IN OPTIONS K9 Aux Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Optional plug in PCBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

DIMENSIONS AND MOUNTING Dimensions & Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-25

WIRINGWiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-31

Conduit plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Input Power wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Motor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Ground Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

INITIAL POWER UP - INTELLIPASS AND INTELLIDISCONNECTInitial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

INTELLIDISCONNECT OPERATION (STARTING / STOPPING OF THE MOTOR)Intellidisconnect Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

INTELLIPASS OPERATION (STARTING / STOPPING OF THE MOTOR)Intellipass Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Drive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

HOA Control - IntelliPass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Key Parameters related to proper IntelliPass Bypass operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

INTELLIPASS/INTELLIDISCONNECT TECHNICAL INFORMATIONTechnical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

3

Contents


General

This document provides supplement information to the JC-VSD Series installation Manual LIT-12011775 specific to the JC-VSD Series II IntelliPass and IntelliDisconnect products. These products are offered with input/output voltages of 208, 230 & 480 VAC with HP ranges from 1 to 75hp. Both UL Type 1 and Type 12 enclosures are available along with several factory wired power and plug in options.

For drive setup and operation I.e. Application, Keypad use, Drive and motor parameters setup, see the quick start guide LIT-12011775 included with the drive. The drive start up wizard can be used to complete the process. For more informa-tion on speed control and other JC-VSD Series II drive features see JC-VSD Series II Application Manual LIT-12011771. The Application Manual and can be found at

http://www.johnsoncontrols.com/

Catalog/Style Numbering

VS 2D2 4 1 1 B - S 0 0 0 0

096Base Product:

RS-485 Communications:VS = VSD Series II Revision:

0 = STD (BACnet / N2 Bus / Modbus)S = SA Bus, CS card (JC-VSD only) Slot D/EB = Rev 2 (Americas)

D = Rev 2 (Canada)

Voltage: Intellipass / IntelliDisconnect Options:Enclosure Rating:

1 = 208V2 = 230V4 = 480V5 = 575V

Drive Style: 0 = STD (BACnet / N2 Bus / Modbus)00 = NoneM1 = Manual Bypass Switch - on front door (for FS 4-7 IPASS that includes L4 = HMAX Pilot Lights )P3 = Drive Isolation Fuses (for FS 4-7 IPASS & IDisc - not available with IPASS, P6 option)P4 = Drive Output contactor (IDisc only)P6 = Drive Isolation Contactor includes drive test switch (for FS 4-7 IPASS - not available with P3 option)P7 = Drive Isolation Fuses and Drive Output Contactor (IDisc only)P9 = Both P3 and P6 available only in Type 3R (or larger FS8 & FS9 Type12 boxes)L3 = HMAX Pilot Lights (IDisc only) L4 = HMAX Pilot Lights (IPASS only) _ = Space Header (Type 3R only)

1 = Nema-UL Type 1 (IP21)2 = Nema-UL Type 12 (IP54)3 = Nema-UL Type 3R (IP22)

1 = Intellipass2 = IntelliDisconnect

NEC 208 Volts 3-Phase: NEC 480 Volts 3-Phase: NEC 480 Volts 3-Phase:

4D6 = 4.6 Amp (1 Hp, 0.75 kW)7D5 = 7.5 Amp (2 Hp, 1.5 kW)011 = 10.6 Amp (3 Hp, 2.2 kW)017 = 16.7 Amp (5 Hp, 4 kW)025 = 24.2 Amp (7.5 Hp, 5.5kW)031 = 30.8 Amp (10 Hp, 7.5 kW)047 = 46.2 Amp (15 Hp, 11 kW)060 = 59.4 Amp (20 Hp, 15 kW)075 = 74.8 Amp (25 Hp,18.5kW)088 = 88 Amp (30 Hp, 22 kW)xxx = xx Amp (40 Hp, 30 kW)xxx = xxx Amp (50 Hp, 37 kW)xxx = xxx Amp (60 Hp, 45 kW)xxx = xxx Amp (75 Hp, 55 kW)

4D2 = 4.2 Amp (1 Hp, 0.75 kW)6D8 = 6.8 Amp (2 Hp, 1.5 kW)9D6 = 9.6 Amp (3 Hp, 2.2 kW)016 = 15.2 Amp (5 Hp, 4 kW)022 = 22 Amp (7.5 Hp, 5.5 kW)028 = 28 Amp (10 Hp, 7.5 kW)042 = 42 Amp (15 Hp, 11 kW)054 = 54 Amp (20 Hp, 15 kW)068 = 68 Amp (25 Hp, 18.5 kW)080 = 80 Amp (30 Hp, 22 kW)104 = 104 Amp (40 Hp, 30 kW)xxx = xxx Amp (50 Hp, 37 kW)xxx = xxx Amp (60 Hp, 45 kW)xxx = xxx Amp (75 Hp, 55 kW)xxx = xxx Amp (100 Hp, 75 kW)xxx = xxx Amp (125 Hp, 90 kW)

2D1 = 2.1 Amp (1 Hp, 0.75 kW)3D4 = 3.4 Amp (2 Hp, 1.5 kW)5D6 = 4.8 Amp (3 Hp, 2.2 kW)7D6 = 7.6 Amp (5 Hp, 4 kW)011 = 11 Amp (7.5 Hp, 5.5 kW)014 = 14 Amp (10 Hp, 7.5 kW)021 = 21 Amp (15 Hp, 11 kW)027 = 27 Amp (20 Hp, 15 kW)034 = 34 Amp (25 Hp, 18.5 kW)040 = 40 Amp (30 Hp, 22 kW)052 = 52 Amp (40 Hp, 30 kW)065 = 65 Amp (50 Hp, 37 kW)077 = 77 Amp (60 Hp, 45 kW)096 = 96 Amp (75 Hp, 55 kW)xxx = xxx Amp (100 Hp, 75 kW)xxx = xxx Amp (125 Hp, 90 kW)xxx = xxx Amp (150 Hp,110kW)xxx = xxx Amp (200 Hp,132kW)xxx = xxx Amp (250 Hp,160kW)

VS-XMX-B2 = 1 RO (NC/NO), 1 RO (NO), 1 ThermistorVS-XMX-B4 = 1 AI (mA isolated), 2 AO (mA isolated)VS-XMX-B5 = Card-3 Relay Dry Contact VS-XMX-B9 = 1 RO (NO), 5 DI 42 – 240V AC InputVS-XMX-BF = Expander IO - 1*AO, 1*DO, 1*ROVS-XMX-CS = SA Bus (JC-VSD only)VS-XMX-C4 = Lon Works Comm CardI/O Options in Slot B (Ordered Separately) VS-XMX-F1 = 3 relay 2 from C, 1 from A (spare/replacement part only- not option w/standard VSD)VS-XMX-F2 = 2 relay 1 from C, 1 from A and 1 Thermistor- not available with L3/L4 Pilot light option replaces standard Relay1 pcb in Slot B and Fault Relay functionParts (Ordered Separately) VS-REM-USB-LOAD = USB to RJ-45 cable with software driverVS-RMT-KEYPAD2 = Series II Keypad Remote Mounting KitVS-KEYPAD-SER2 = Series II Graphic Bypass HOA Keypad

Options (Ordered Separately) VS-XMX-K9-FS4-5 = Aux Contacts - Qty 2 (FS4-5 Bypass and Drive Output Contactors)VS-XMX-K9-FS6-9 = Aux Contacts - Qty 2 (FS6-9 Bypass and Drive Output Contactors) Extended I/O & Comm Options in Slot D & E (Ordered Separately) VS-XMX-B1 = 6 DI or DO, 1 ext +24V DC/EXT +24V DC Programmable VS-XMX-B2 = 1 RO (NC/NO), 1 RO (NO), 1 Thermistor

Extended I/O & Comm Options in Slot D & E (Ordered Separately) VS-XMX-B1 = 6 DI or DO, 1 ext +24V DC/EXT +24V DC Programmable

JC-VSD II Series Master Product Part Number Matrix - Open and IPass/IDisc

*

*

Solutions pending. Contact a Johnson Controls Sales Representative for availability.*

4

General


Identification

Unit ID labelsJC-VSD Series II IntelliPass/IntelliDisconnect Carton Label

JC-VSD Series II IntelliPass/IntelliDisconnect Nameplate

Use table in the next page to determine enclosure frame size based on Hp.

30-16557-2

Assembled in USA987654321012

Cat. No.QtyIntellipass

JCNI98765-40C to 70C (-40F to 158F)

3-3188-153A

1

120418

VS011111B-0P6003 Hp @ 208VAC 10.6A

Style No:

Storage Temp:

JC-VSD Series IIMax HP:

Order No:

AOMS No:

T

JOB# 2000 AIR UNIT # 1Cust.Ref No:65432

www.johnsoncontrols.com

Options: P6

IND. CONT. EQ.77Y6

®

IND.CONT.E Q.77Y6

®

www.johnsoncontrols.com

Enclosure Type:Short Circuit Ratings:

See IS Manuals for more information:

99775533

Schematic:

T

VS011111B-0P600Catalog No:

Max Ambient Temp:

Order No:

1

Intellipass

Field installed conductors must be copper rated at 75°C.

Input:Output:Max HP:

0-208VAC 0-320Hz 10.6A208VAC 50/60Hz 10.6A

LIT-12011775

3 Hp @ 208VAC 10.6AControl: 24VDC

40C

JC-VSD Series IIStyle No: 3-3188-153A

AOMS No:

285447-1008

LIT-12011772 and

65KA @ 208VAC

654321ØJCNI98765

Assembled in USA

Serial No:

120418

Options: P6

5

Identification


6

Identification


Use table below to determine enclosure size and frame size based on Hp.

Enclosure Size and drive Frame size Indenfication

Volts Hp Current Drive Size Standard Enclosure Type 1/12

3R and OversizeEnclosure type 1/12

208 1 4.6

4 Size 4

A

2 7.5

3 10.6

230 1 4.2

2 6.8

3 9.6

480Y/277 1 2.1

2 3.4

3 4.8

5 7.6

7.5 11

208 5 16.7

5 Size 5

7.5 24.2

10 30.8

230 5 15.2

7.5 22

10 28

480Y/277 10 14

15 21

20 27

208 15 46.2

6 Size 6 B

230 15 42

480Y/277 25 34

30 40

40 52

208 20 59.4 6

Size 7 C

25 74.87

30 88

230 20 54 6

25 68

7

30 80

40 104

480 50 65

60 77

75 96

ComponentsIPass and IDisc Typical Component locations.

Typical Component Locations

An Eaton Green Solution

2 3

32

4

4

DRIVEINPUT

ISOLATIONCONTACTOR

“I”

JC-VSD Series II

7

Identification


ComponentsIPass and IDisc Typical Component locations.

8

Identification


Factory Wired Options

The Intellpass and IntelliDisconnect can be supplied with serveral factory wired power options. The table 1 and sections below describe the options.

Options

HMAX Option Matrix IPass IDisc

P3 - Drive Isolation Fuses X X

P4 - Drive Output contactor N/A X

P6 - Drive Isolation Contactor includes manual switch X N/A

P7 - Drive Isolation Fuses and Drive Output Contactor N/A X

M1 - Manual Bypass includes L4 and drive isolation contactor and door switch X N/A

L3 – H-Max Pilot Lights N/A X

L4 – H-Max Pilot Lights X N/A

Space Heater (3R only) X X

P3- Drive Isolation FusesThis option is available for both the IntelliPass and IntelliDisconnect designs 208/230V up to 30Hp and 480V models up to 75 hp.

3 Power Fuses are supplied wired to the Drive input. They are provided between the disconnect device and drive. The fuses are not used in the bypass mode. The fuses are for drive protection only. They are listed, Class CC or Special Purpose Fuse cube fuses sized according to the following table. This option cannot be used with P6 isolation contactor option. See IntelliDisconnnect or Typical IntelliPass schematic.

Hp Rating and Fuse Rating (A)

HP 208 V Fuse 230 V Fuse 460 V Fuse

1 6 6 5

2 12 12 6

3 20 20 8

5 25 25 12

7.5 30 30 20

10 45 45 25

15 60 60 30

20 80 80 45

25 90 90 45

30 100 100 50

40 N/A N/A 60

50 N/A N/A 80

60 N/A N/A 90

75 N/A N/A 100

9



CCC Fuses (P3 option) Cube Fuses (P3 option)

P3 Drive Fuse Option

10



P4 - Drive Output contactorThis option is available for IntelliDisconnect models only. This option provides a contactor wired to the Drive output. The motor is then wired to the contactor. The output contactor is controlled by the Drive so when the Drive is stopped the con-tactor drops out and when the Drive is in a run mode, the output contactor is energized and connects the Drive to the motor. A 24 volt power supply is also provided to power the contactor. Provisions for and external interlock is also provided. See IntelliPass schematic with P4 option.

IntelliDisconnect P4 Output Contactor Option

PS

L

N

24V 2.5A

-+

50-60Hz100-240V~ 1.5A

DC OK

Adjust

11



P6 – Drive Isolation Contactor includes Drive test switchThis option is only available on the IntelliPass models. An input contactor is supplied wired to the drive input and a manual 2 position selector switch is provided to control the contactor. The switch is located inside the enclosure on the door. The enclosure door must be opened to operate this switch. See typical IntelliPass schematic.

The contactor removes main power from the Drive. The Drive display and logic will remain active because of the separate 24Volt power supply, but the Drive will not run. The Drive Keypad is still powered and the bypass feature remains operational and the motor can be run in bypass using the keypad. The input contactor “I” is energized at all times while in the drive mode if the door mounted selector switch us in the on position. This option cannot be used with M1 Manual Bypass or P3 fuse options.

P6 Drive Isolation Contactor Option Typical View Frames 4 - 6 (FR4 Shown)

Switch on inside of door

Input contactor

P6 DRIVE ISOLATION CONTACTOR OPTIONTYPICAL VIEW FRAMES 4-6 (FR4 SHOWN)

2 3

32

4

4

12



P7 - Drive Output Contactor and Drive Isolation Fuses

(IntelliDisconect Only)

OUTPUT CONTACTOR

13



M1 - Manual Bypass (forced) SwitchThis option is available on the IntelliPass models only. This option includes an input contactor “I”, L4 pilot light option and a 3 position door mounted selector switch - marked Drives/Off/Bypass. This switch manually overrides the Bypass control from the system (keypad) and puts unit in bypass or in an OFF mode. See IntelliPass Schematic with M1 option.

When the door switch is in the Drive position, the JC-VSD Series II Drive logic controls the motor and the keypad selects the operation (Drive or Bypass), the control source and place (HOA, KEYPAD or Terminal block). The input contactor “I” is ener-gized at all times while in the drive mode.

When the door switch is moved to Bypass, three actions occur: 1) Drive input isolation contactor is forced open, 2) Drive output contactor will be forced open and the bypass contactor will be forced closed. The motor will immediately start and run full speed across the line regardless of the state of the system or drive.3) The Drive will be forced to the bypass mode and the Keypad Display will show “Bypass”. When the switch is moved back the Drive position, Drive operation is restored and the system may need to be restarted.

When the switch is in the off position neither the drive or bypass operation is possible. Moving the Switch to the off or bypass position while the Drive is operating may cause the Drive to fault because the input power to the drive is removed by the input contactor. See L4 for description/operation of the door mounted pilot lights.

Manual Bypass Option M1

M1 Option


2 3

32

4

4

3R Versions have Bypassswitch located in Keypad Enclosure

14



Space Heater Option (Type 3R enclosures only)This option aids in preventing or reducing condensation from forming in the enclosure when the drive is inactive. A 120V 100W heater is installed in 3R enclosures size A & B and a 200W heater are installed in enclosure size C. A control trans-former and fusing is also provided to power the heater. See schematics for more information. The heater includes a user adjustable thermostat for variable temperature control and an internal fan. See pictures

SETTING THE THERMOSTATThe heater is controlled by an adjustable thermostat. Set the thermostat to the desired temperature. It is recommended not to exceed 75 F for most applications. The heater is active at all times when the main disconnect is closed including when in the Drive, Off or Bypass operation. However, depending on the setting of the thermostat, the internal heat generated by the system when in operation should be enough to turn off the heater. Generally the heater requires no maintenance since the fan bearings are permanently lubricated and sealed.

Heater

ControlTransformer

Heater FusesSee Schematic

Heater Thermostat Adjustment

15



L3/L4 - HMAX Pilot LightsThe L3 option is available only on the IntelliDisconnect models and provides 3 door mounted pilot lights, 1 red, 1 white and 1 green. The L4 option is available on the IntelliPass models and provides 4 door mounted pilot lights: 1 red, 1 white, 1 green and 1 amber.

L4 Option L3 OptionThe white “Power On” light indicates that 24VDC power is active. However, Caution is advised if the light is not illuminated, as this is may not be an indication that main power has been removed. If the light fails or the 24V power supply fails, main power may still be present. Always follow proper safety procedures to determine the presence of main power on the unit

The red “Drive Fault” light indicates a Drive fault is present.

The green light indicates the system is commanded to run from the Drive and the Drive is in the “run” mode, the drive out-put contactor is also energized if the PE option is supplied. The speed of the motor will depend on the Drive speed signal. The motor may not be rotating if commanded at zero speed.

The amber light indicates the system has been commanded to run in bypass. The bypass contactor should be energized and the motor running across the line.


16



Plug in options

K9 Aux ContactsThis option adds 1 N.O. & N.C. auxiliary contacts to both the Drive output and bypass contactors for customer use.

K9 Aux Contact Applications

Product Frame Hp Voltage Qty Eaton P/N Description

IPass 4 ALL ALL 2 VS-XMX-K9-FS4-5 Aux NO, NC Contact, B/C frame Top Mount

IPass 5 ALL ALL 2 VS-XMX-K9-FS4-5 Aux NO, NC Contact, B/C frame Top Mount

IPass 6 ALL ALL 2 VS-XMX-K9-FS6-9 Aux NO, NC Contact, D/F/G frame Top Mount

IPass 7 ALL ALL 2 VS-XMX-K9-FS6-9 Aux NO, NC Contact, D/F/G frame Top Mount

IDisc 4 ALL ALL 1 VS-XMX-K9-FS4-5 Aux NO, NC Contact, B/C frame Top Mount

IDisc 5 ALL ALL 1 VS-XMX-K9-FS4-5 Aux NO, NC Contact, B/C frame Top Mount

IDisc 6 ALL ALL 1 VS-XMX-K9-FS6-9 Aux NO, NC Contact, D/F/G frame Top Mount

IDisc 7 ALL ALL 1 VS-XMX-K9-FS6-9 Aux NO, NC Contact, D/F/G frame Top Mount

Optional plug in PCBS A number of plug in option cards are available. A maximum of 2 option cards may be factory installed in the control module slots. Available options are shown in table 5.

Typical Plug in Option PCB

See the option manual included with each PCB for more information.

17

Plug in options


Also see JC-VSD Series II Installation manual LIT-12011772 for more information on control wiring, control board layout and options PCBs.

Dimensions & Mounting

The IntelliPass/IntelliDisconnect physical dims are based on the Enclosure frame size. See Table 1 to determine the enclosure frame size based on Hp and voltage.

• Weights and lifting provisions are on the dimension section and with the drawing provided with the unit

• Attach “load-rated” hooks or shackles to lifting eyes on back panel.

• Always maintain a maximum of 45 degrees between the lifting cables and the vertical plane.

• Do not pass ropes or cables through the lifting eyes as sharp edges may cause excessive wear and possible failure.

• Select or adjust rigging lengths to compensate for unequal weight distribution of the load to keep unit in the upright position.

The hardware to mount the Intellipass/IntelliDisconnect units, all frame sizes, is as follows:

3/8-16 Grade 5 Hex Head Bolt, with 3/8 lock washer and 3/8 flat washer. QTY 4 of each required. Torque to 20 lb-ft.

Opt

ion

Conf

ig

VFD

Fr

ame

Volta

ge

HP

Qty

P/N Description

B1 All All All All 1 VS-XMX-B1 I/O Expander Card, 6 DI/DO, Slot D/E VS-XMX-B1

B2 All All All All 1 VS-XMX-B2 I/O Expander Card 2 x RO + Thermistor, Slot D/E VS-XMX-B2

B4 All All All All 1 VS-XMX-B4 I/O Expander Card 1 x AI, 2 x AO (isolated), Slot D/E VS-XMX-B4

B5 All All All All 1 VS-XMX-B5 I/O Expander Card 3 x RO, Slot D/E VS-XMX-B5

B9 All All All All 1 VS-XMX-B9 I/O Expander Card 1 x RO, 5 x DI (42-240VAC), Slot D/E VS-XMX-B9

BF All All All All 1 VS-XMX-BF I/O expander Card, 1 x AO, 1 x DO, 1 x RO, Slot D/E VS-XMX-BF

C4 All All All All 1 VS-XMX-C4 LonWorks, Slot D/E VS-XMX-C4

CS All All All All 1 VS-XMX-CS SA Bus, slot D/E

18



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24



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26



Wiring

Schematic A schematic is included with each product. The schematic number can be found on the product nameplate.

Typical schematics are shown on the next few pages.

NOTE:

Power and Motor Leads must be in separate conduit.

Do not run control wires in same conduit as input power or motor wires

Two grounding points are provided, input ground and output ground

Ground unit properly – improper grounding could damage the unit

27

Wiring


Inte

llidi

scon

nect

Sta

ndar

d - (

Spa

ce H

eate

r S

how

n)

Dw

g R

ef: 2

8544

6-10

01

28

Wiring


Inte

llidi

scon

nect

with

P7

optio

n O

utpu

t C

onta

ctor

and

Isol

atio

n Fu

ses

(Spa

ce H

eate

r S

how

n)

Dw

g R

ef: 2

8544

6-10

07

29

Wiring


Inte

llidi

scon

nect

with

P3

optio

n Is

olat

ion

Fuse

s (S

pace

Hea

ter

Sho

wn)

Dw

g R

ef: 2

8544

6-10

03

30

Wiring


Inte

llipa

ss S

tand

ard

- No

optio

ns (S

pace

Hea

ter

Sho

wn)

Dw

g R

ef: 2

8544

7-10

01

31

Wiring


Inte

llipa

ss w

ith M

1 op

tion

Man

ual B

ypas

s (S

pace

Hea

ter

Sho

wn)

Dw

g R

ef: 2

8544

7-10

02

32

Wiring


Conduit platesThe IntelliPass and IntelliDisconnect have removable top and bottom conduit plates to make wiring and conduit connections easier. See Dimension and Mounting section for access areas.

33

Wiring


Input Power wiringInput power connection are made to the disconnect device. Input power connection points are identified by Label (L1, L2 and L3).

Both IntelliDisconnect and IntelliPass provide a input disconnect by using either a UL Listed, Manual Self-protected Combination Motor Controllers (Type E), Models XTPR or a Listed molded case circuit breaker, Models HFDMP sized as indicated below, Line Side Adapter ( model XTPAXLSA or XTPAXLSAD) are provided with the XTPR Type E devices. These devices provide a disconnect function, Branch protection/short circuit protection and when used in the IntelliPass, Class 10 Motor overload protection while running in bypass. Adjust the dial for proper Motor FLA.

Typical Input Power Connection Point Labels

Connect Input Power Wires here

Both Intellidisconnect and Intellipass provide an input disconnect by using a UL Listed, Manual Self-protected Combination Motor Controllers (Type E), Model XTPR or a listed molded case circuit breaker, Models HFD sized as indicated in on page 35. Line Side Adapter (Eaton model XTPAXLSA or XTPAXLSAD) is also provided with the XTPR Type E devices.

These devices provide a disconnect function and the IntelliPass models branch protection/short circuit protection and Class 10 Motor overload protection while running in bypass. These devices are factory adjusted to the nameplate value of unit- see page 35. If necessary adjust the dial for proper Motor FLA -see examples below.

If Necessary,Set Motor FLA here

Value is Factory Set to Nameplate Value

See page 35

If Necessary, Remove Operator Mechanism to Access Setting Dials

to set Motor FLA Value is Factory Set to Nameplate

Value See page 35

34

Wiring


Input Wiring Details

Torque

Volts Hp CurrentEaton P/N Branch protection or Disconnect

FLA Adj Range

Instructions See Eaton.com

Eaton P/N LSA Adapter Wire range lb-in N-m Tool

208 1 4.6 XTPR6P3BC1 4-6.3 PUB51173 MN03402005e

XTPAXLSA

14-6 35 4

0.8 x 5.5 1 x 6 mm (flat) Size 2 pozidriv

2 7.5 XTPR010BC1 6.3-11

3 10.6 XTPR012BC1 8-12

230 1 4.2 XTPR6P3BC1 4-6.3

2 6.8 XTPR010BC1 6.3-11

3 9.6 XTPR012BC1 8-12

480Y/277 1 2.1 XTPR2P5BC1 1.6-2.5

2 3.4 XTPR004BC1 2.5-4

3 4.8 XTPR6P3BC1 4-6.3

5 7.6 XTPR010BC1 6.3-11

7.5 11 XTPR012BC1 8-12

208 5 16.7 XTPR025DC1 20-25 MN03402004e XTPAXLSD

8-0 54 6

4mm Hexagon socket-head spanner

7.5 24.2 XTPR025DC1 20-25

10 30.8 XTPR032DC1 25-32

230 5 15.2 XTPR016DC1 10-16

7.5 22 XTPR025DC1 16-25

10 28 XTPR032DC1 25-32

480Y/277 10 14 XTPR016DC1 10-16

15 21 XTPR025DC1 16-25

20 27 XTPR032DC1 25-32

208 15 46.2 XTPR050DC1 40-50

230 15 42 XTPR050DC1 40-50

480Y/277 25 34 XTPR040DC1 32-40

30 40 XTPR050DC1 40-50

40 52 XTPR058DC1 50-58

35

Wiring


Torque

Volts Hp CurrentEaton P/N Branch protection or Disconnect

FLA Adj Range

Instructions See Eaton.com

Eaton P/N LSA Adapter Wire range lb-in N-m Tool

208 20 59.4 HFDMP3080JL 40-80 IL29C115C N/A

14-10 35 4

Slotted Head

25 74.8 HFDMP3080JL 40-81

30 88 HFDMP3100JL 80-100

230 20 54 HFDMP3080JL 40-808 40 4.5

25 68 HFDMP3080JL 40-80

30 80 HFDMP3100JL 80-100

6-4 45 5.140 104 HFDMP3160JL 100-160

480 50 65 HFDMP3080JL 40-80

60 77 HFDMP3080JL 40-803 - 4/0 50 5.6

75 96 HFDMP3100JL 80-100

HFDMP FLA DIAL setting

HFDMP A B C D E

80A 40 50 60 70 80

100A 80 * 90 * 100

160A 100 115 130 145 160

36

Wiring


Motor WiringMotor connection points are identified by a label (1TA,1TB,1TC). See Output wiring table in technical section for wiring and torque information. Also see JC-VSD Series II Installation manual LIT-12011775 electrical schematics for more details on con-nections to drive output terminals when an output contactor is not supplied.

For IntelliPass models, wire the motor leads directly to the output contactor O. Motor connections are made directly to the bottom of the output contactor on the lower right side (see examples below)

Typical Motor Connection Point Label

Typical IntelliPass with 3 Contactors

Input/Isolation Contactor"I"

Output Contactor "O"

Bypass Contactor "B"

Output Contactor "O"Bypass Contactor "B"

Typical IntelliPass with 2 Contactors

37

Wiring


Paralleling Bridge

Paralleling Bridge

Frame 7Motor Connection Pointsare above parallel bridge

Remove Drive Cover andMetal Terminal Covers to

Expose Output TBConnections on Drive

Connect Motor LeadsDirectly to the Drive Output

TB

Intellipass Frames 4-7Motor Connection Points are

below parallel bridge

For IntelliDisconnect models, wire directly to the drive output terminals or to the output contactor if the P4 option is supplied.

38

Wiring


Output Wiring Details

Horse Power Rating Contactor’s Current Rating(Amps) {AC-1}

Eaton Contactor P/N

InstructionsSee Eaton.com

Wire rangesee note

TorqueTool

208 V 230 V 460 V lb.-in N-m

1, 2, 3 1, 2, 3 1,2,3, 5, 7.5,

22 XTCE007B pub51210 IL03407014Z

18-14 single/double

11 1.2 0.8 x 5.5 1 x 6 mm (flat) Size 2 pozidriv

5, 7.5, 10

5, 7.5, 10

10, 15, 20

40 XTCE018C pub51232 pub51211 IL03407014Z

14-8 single/double

28 3.2 0.8 x 5.5 1 x 6 mm (flat) Size 2 pozidriv

15, 20 15, 20 25, 30,40

60 XTCE040D pub51216 IL03407033Z

14-1 single 12-2 dual

29.2 3.3 0.8 x 5.5 1 x 6 mm (flat) Size 2 pozidriv

- - 50 98 XTCE065D

25, 30 25, 30 60 110 XTCE080F pub51188 IL03407039Z

8-3/0 single 8- 2/0 double

124 14 5mm Hexagon socket-head

- 40 75 160 XTCE115G

Note: For IntelliPass models two wires per terminal is not allowed because the factory installed paralleling bridge uses one connection point

39

Wiring


Ground WiringBoth input and output ground studs are provided and marked with label. Hardware is also supplied.

Frames 4 thru 6 have 10-32 studs on the back panel, and the supplied nut, flat washer and lock washer should be torqued to 30 lb-in

Frame 7 has 1/4-20 studs on the back panel, and the supplied nut, flat washer and lock washer should be torqued to 65 lb-in

Control WiringNo additional control wiring is necessary for basic operation - see schematic for Auto Start contact, Auto reference connec-tions and interlock connections to control PCB terminal block if required.

See JCI-VSD Series II Installation manual LIT-12011775 electrical schematics for more information on control wiring and con-trol board layout and connections.

For ease of access the control terminals blocks can be unplugged for wiring.

All control I/O wiring must be segregated from line (mains) and motor cabling.

Run 120 Vac and +24 Vdc control I/O in separate conduit if applicable.

Control I/O terminals must be tightened to 4.5 lb (0.5 Nm).

In addition, the IntelliPass models provide an additional “External Interlock” input on TBA 2 & 3. This can be used to remove the 24V power from the contactors and door control elements. If is factory jumpered. If removed, it removes 24V power to the bypass and drive contactors. It does not disable the drive from running, only from being connected to a motor. Under some circumstances the drive/bypass could still be commanded to run but since the contactors are disabled, the motor will not run, however the drive keypad may indicate it is running. Refer to the schematic

This external interlock input is not supplied on the IntelliDisconnect models unless the output contactor with power supply option is supplied. Refer to the schematic.

Typical Ground Stud and Labels

Typical TBA Interlock

Interlock jumper from 2-3installed at factory

Input Output

40

Wiring


Initial Power up - IntelliPass and IntelliDisconnect

When the IntelliPass or IntelliDisconnect is first powered up, the startup wizard command should be displayed.

Follow the Quick Setup guide LIT-12011773 to set up Drive for your specific application with the following exceptions:

When the Bypass screen appears set it to “Enabled” for IntelliPass and “Disabled” for IntelliDisconnect Models

IntelliDisconnect Operation (starting/stopping of the motor)

IntelliDisconnect operation is the identical to a standard JCI-VSD Series II open Drive. The only difference is that an input disconnect is provided. For more information on Speed control and other Drive features see Application Manual LIT-12011771. See option sections for more information on operation of IntelliDisconnect options i.e. Drive output contactor.

IntelliPass Operation (starting/stopping of the motor)

The IntelliPass operation is similar to the IntelliDisconnect but has the added feature of a built in Drive Bypass. This section gives basic information on operations for controlling the starting and stopping of the motor in both the Drive and Bypass modes. For more information on Speed control and other Drive features see Application Manual LIT-12011771

The IntelliPass has 2 modes:

Drive mode (normal VFD operation),

Bypass mode (across the line).

The mode is selected via the Keypad. The actual starting and stopping of the motor is determined by the HOA selection and the Control Place selections. The Control place is defined as the location from where the Drive is started and stopped. The control place can be: Keypad start button, I/O contacts wired to the logic terminal blocks, Fieldbus control or PC. See Quick Start Guide LIT-12011775 or Application Manual LIT-12011771 for more information.

The only exception is if the M1 Manual Bypass option is supplied, this option can override the Drive logic and can start the motor in Bypass immediately.

41

Initial Power up - IntelliPass and IntelliDisconnect


Drive ModeWhen the IntelliPass is in the Drive mode, the text “E-Energy” is shown on status bar. (If E-Energy function is not active the text “Ready” will be shown)

When the system is first commanded to run, the output contactor O is energized and the motor is connected to the Drive. The “O” contactor is controlled by the IntelliPass logic via Relay 2 output. The speed of the motor is determined by the speed set point of the JCI-VSD Series II Drive. When the JCI-VSD Series II is commanded to stop, the Drive will reduce the speed of the motor and when the motor speed reaches zero, the output contactor “O” is de-energized and the motor is dis-connected from the IntelliPass. The output contactor also opens immediately if there is a Drive fault. (See Schematic)

The IntelliPass system is also interlocked. When the output contactor ”O” is energized, the Bypass contactor “B” is pre-vented from being energized by electrical interlocks in each contactor coil control circuit and a logic interlock built in to the IntelliPass software. (See Schematic)

Bypass ModeWhen the IntelliPass is in the Bypass mode, the text “Bypass” is shown on status bar.

When the system is commanded to run in the Bypass mode, the motor is connected to the line through the Bypass contac-tor (B). The B contactor is controlled by the Drive logic via a Relay 1 output.

The Bypass mode can be selected in 3 ways:

• Manually via the Drive logic controls (i.e. Keypad, Fieldbus or I/O).

• Automatically after a Drive fault - if the Auto Bypass feature is active.

• Manually by a door switch (Option) - Manually using the manual Bypass switch as part of the option M1.

Manual Bypass

Manual Bypass can be activated either by using the Bypass button on the keypad, by using a digital input on the control TB or from the Fieldbus. The user can toggle between Bypass and Drive modes by pressing the keypad Bypass button or the TB inputs. Once in the Bypass mode, the start command can be given through any control place (I/O, Keypad, and Fieldbus) in the same manner as starting in the Drive mode.

IntelliPass Operation (starting/stopping of the motor)42



Using the keypad to select Bypass Mode:

When the Bypass button is pressed, the following options are shown to the user. Select the desired mode by using the arrow keys and pressing the OK key.

The user can toggle between modes by pressing the Bypass button again. If Bypass button is pressed while the Drive is running, the keypads will display “Bypass is not allowed”. The system must be stopped to allow a change from Drive to Bypass mode. Likewise if the system is running in Bypass and the Bypass key is pressed the display will indicated “Motor Running in Bypass” To change state back to Drive the system must be stopped. The keypad will display Bypass in the Status display when in the Bypass mode and Ready or E-Energy when in the Drive mode

Using the digital input to select Bypass Mode:

If the digital input (Force Bypass) is used to enable the Bypass mode, the Drive will ramp to zero speed. Once the Drive stops, the Bypass mode is active and the keypad will display the Bypass mode. The Bypass and motor will start when a valid start command is received. Note that the Force Bypass function is the factory default for Digital Input #6 P2.3.6.2 locat-ed at TB16 on the control module and is also factory wired to the M1 Manual Bypass option if supplied.

Using the Fieldbus to select Bypass Mode:

The Fieldbus command works the same as the digital input.

Auto Bypass operation

The Drive can also be Bypassed automatically if certain faults occur. When the selected fault occurs, the Drive is first stopped. Then, depending on the Automatic Reset parameter, the Drive is either Bypassed instantly or the fault is first tried to reset. If the reset fails, the motor is automatically started in Bypass.

When the Drive goes to Auto Bypass, the keypad displays “Going into AutoBypass” for 10 seconds. After the delay, the Drive goes to the Bypass mode and starts the motor (the run command must still be present).

43



When the fault condition is not active, the Drive is set back to Drive mode automatically and the Bypass running signal is reset. The Drive returns to the normal operation.

Automatic Reset selections 0 = Not used

1 =Auto Bypass (Visible only if Bypass is enabled)

2 = Reset faults

3 = Reset/Bypass (Visible only if Bypass is enabled)

Activate the Automatic Reset functions with this parameter.

For option 1, if the Drive faults, the Drive switches automatically to Bypass and leaves the fault active on the Drive. For option 3, the Drive will first try to auto reset the faults but if not successful, it will then switch to Bypass. Option 2 just tries to reset the fault without going into Bypass. See the application manual for more information on Auto reset operation.

Manual Bypass (forced) - M1 option

The IntelliPass also has a forced manual Bypass option. This is controlled by a door mounted Drive/Off /Bypass switch. The door switch will start the motor in Bypass immediately regardless of Drive logic or state. This switch manually overrides the system (keypad) and forces the unit into Bypass mode even if the Drive is in operative or removed from the system - See schematic and the factory wired option section for more information.

HOA Control- IntelliPassThe Keypad HOA button is used for fast and easy changing between Hand, Off and Auto control places the change the speed set point source. HOA Control works in both the Drive and Bypass modes of operation. However speed set point has no functions when in Bypass since the motor runs full speed across the line.

Control place is defined as the location from where the Drive or Bypass is started and stopped. Hand and Auto are two dif-ferent control places.

There are four parameters for selecting a control source and reference source for them: P2.1.3 HOA Control Source, P2.1.4 Start Source Hand, P2.1.5 Speed Set point Hand, P2.1.6 Start Source Auto & P2.1.7 Speed Set point Auto. The Start Source selections are: Keypad, I/O Terminal, I/O 3-wire & Fieldbus Ctrl. For the Drive mode, the Speed set point the selections are: Keypad Ref, Fieldbus, AI1, AI2, AI1+AI2, & PID1 (if PID is activated). See Quick Start Guide LIT-12011773 or Application Manual LIT-12011771 for more information.

44



When control place Off is selected, the Drive cannot be started anywhere. It prohibits the start command for both Drive and Bypass. If the M1 option is supplied, the Bypass may force started in the HOA off mode by using the Door switch.

Key Parameters related to proper IntelliPass Bypass operationThe following parameters are related to Bypass functionality and are factory default set. Changing them will affect proper IntelliPass operation.

P2.1.2 Bypass: This parameter is for activating the Bypass functionality. It is factory enabled. If disabled the Bypass keypad button is inactive and some parameters may be hidden. This is part of the Start-up wizard

P2.3.2.2.1 (RO1 Function) set to Bypass Run. This signal is active if the Bypass mode has been selected and the run com-mand is active - this relay output controls the Bypass contactor it should not be changed.

P2.3.2.2.5 (RO2 Function) set to Run. This signal is active if the Drive mode has been selected and the run command is active - this relay output controls the output contactor if should not be changed

P (DI2 Function) - (DI6 Function): set to Force Bypass.

If Force Bypass option has been selected for digital input and the input is activated, the Drive goes to Bypass the next time it is started. If the M1 option is supplied, this input should not be changed.

IntelliPass” Short Circuit Rating

Frame Voltage Available current

4-6 240 Vac, 480Y/277 Vac 65,000 A

7 480 Vac 65,000 A

Intellidisconnect” Short Circuit Rating

Frame Voltage Available current Breaker/Disconnect

4-6 240 Vac, 480Y/277 Vac 65,000 A MMP

7 480 Vac 65,000 A HFDMP

IntelliPass/IntelliDisconnect Technical information

See JCI-VSD Series II Installation manual LIT-12011775 for additional data

Enclosure: Type 1 or Type 12 as ordered

Max Ambient Temp: 40o C

Wire temperature rating of field installed conductors: Use 75o C copper conductors only

45



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© 2012 Johnson ControlsAll Rights ReservedPublication No. LIT12011775 / 004April 2013

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johnson controls variable speed drives series ii

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